AU2015372454A1 - Method and apparatus for pre-treatment of non-continuous textiles - Google Patents

Description

METHOD AND APPARATUS POM PRE-TREATMENT OF NON-CQNT1NDOOS TEXTILES

CROSS-REFERENCE TO RELA TED APPLICATION

[0001] Priority is claimed to ITS, provisional patent application «0. bl/928,bil tiled January I?, 2014,

TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

[0092] The present invention relates to the application of pre-treatments, chemicals, processing aids, and finishing agents to fiber*. garments, arid other nosr-cotttmueus textile* and textile materials (alternatively referred to herein as “textile substrates”), and related apparatus to accomplish same in advance of dyeing the textile substrate. The present invention enables She dyeing of textile substrates using less dye, time, water, and energy than heretofore-.

[0003] It is an object of the present invention to provide a method of applying pretteatmenis, chemicals, processing aids, and finishing agents to fibers, garments and other non- continuous textiles. It is a further object of the invention to provide m apparatus to accomplish the method.

SUMMAR Y OF THE INVENTION

[0004] The invention involves &c- implication of a solution s uch -as one containing an epoxy ammonium compound and an alkaline catalyst to fibers, garments, or other nan-continuous textiles made of cotton or other celhdosic materials. See, for example, international patent application PCr/UB2fil3/O23180 published July 31, 2014 as WO 2014/110230 A!, whose disclosure is incorporated herein In its- entirety. After cotnplete processing, permanent cationic dye sites are thereby attached to the molecules of ceUulosie material. The formation of these dye sites allows the textile substrate to he. dyed most efficiently and completely without having to use corrosive exhaust salts and high temperatures. Scouring and rinsing m4 the attendant use of large amounts of chemicals ami water are drastically reduced. The total process saves sufcstaaiia) amounts of water, energy, time, and 'dyestuff compared to conventional dye processing. The result is an ecologically advantageous sod efficient method that achieves excellent results.

[0005] The method or proem for forming dye sites on the molecules of the cellulosle material uses a modification of eqalpmem similar to that used I» the laundry industry, .1« one embodiment of the mvemtoo, parts of a tunnel washer arc used. A tunnel washer Is a continuous washing device that conveniently includes a loading module on aa input end, several modular washing and rinsing compartments, and a water extractor, such as a hydraulic press, to extract excess liquid at the exit end. The water-extracted textile materials are then transferred to a drying unit to finish the process. |0006] The tunnel washer is not in itself an efficient or economical device for forming the dye sites. However,, by uniquely combining the loading and saturator module 'with the hydraulic press and capturing and ransing the excess solution, an economical ecologically efficient, and sustainable way of applying she liquid to non-eonfirmous textiles is achieved. Intermediate washing and rinsing modules can accordingly be; eliminated* molting in a new apparatus that, earnest oat a pre-finishing procedure quickly and efficiently, lie impregnated textile substrate is stored or "batched* for a finite period (e.g.,. 8 to 24 hours at room temperature) until the reaction, between the eellalosic material and the pre-treatment solution is completed, forming the dye sites on the molecules of the cellulosic textile substrate. Batching is the most energy efficient method of carrying out this reaction. The dye site formation'process can also be accelerated fay heating, steaming, or drying, the onpregtratsd textile under carefully eoatKdbd and monitored conditions.

[0007] ίο accordance with one embodiment of the invent!®», a method of pm4fcating textiles in advance of dyeing them includes the steps of loading the textile into a vessel and saturating the textile with pm-treaiment chemicals. The saturated textile and excess solution are transferred into a hydraulic press similar to the type used .for dewatering with a tunnel wash unit in laundries. Excess ehetnietd solution is required to ensure total impregnation of the textile substrate being processed.. The press is engaged and uniformly squeezes the textile substrate to distribute the chemical equally throughout the textile substrate and to produce a predetermined moisture content of between about 63% and 140% by weight. The excess chemicals are extracted from the textile: substrate .and repeatedly recirculated back iato the vessel for reaction with one or more subsequent Ibad{$) of textile substrate. The textile substrate containing the remaining absorbed and sqyeeml chemical solution is tbeu, in the same way as is described above, batched to form the dye site.

BRIEF DESCRIPTION OF 'ΓΗΕ DRAWINGS

[0008] The present ktveaiion is best understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which; [00091 Figure-1 is a Sow diagram of a method of pre-treating textiles, according to one embodiment of the invention; and [00010] Figure. 2 is a cross-sectional view of a press of a type normally used for dewatering wife tunnel wash units. Figures 3, 4, end 5 am sequential views showing the substrate loading, pressing,, and unloading, respectively in the operation of the press of Figure 2,

DETAILED DESCRIPTION

[000111 Referring specifically to the thawings, a method and apparatus according to a preferred embodiment -of the invention am illustrated. The process begins with a loading sod saturating step whetem fee textile substrate, which can he libers, yarns, or tahrknted goods such as hosiery or other apparel, is loaded into a vessel wherein the goods are tumbled, oscillated or otherwise mechanically agitated in the saturator «sit in. the presence of pre« treatment chemicals to ensure complete sad thorough wetting of the textile substrate to site point of complete saturation, The cellulosic textile material is thus saturated with a ««.Jetton containing a cationic molecule, an alkaline catalyst, and wetting surfactant Saturatlon result* in the e&emkal solution imprecating 100% of the textile substrate so that the maximum number of dye sites being available for processing -are formed. The type of vessel is critical m that all of the textile substrate is exposed to and absorbs the chemical, solution. The textile-substrate Impregnated with-the solution and pressed to a predetermined· moisture content is hatched to allow the reaction to form permanent cationic sites. (00012] As also shown in. Figure 1, the impregnated textile material is unloaded from the vessel and pieced into a press, such m the hydraulic press 1 shown in Figure 2 via a slide 10 as shown in Figure 3. A hydraulic press such as the type that, is deployed in commercial isnMries typifies an apparatus suitable for adaptation for use in the present invention. As shown in Figures J through 5, the hydraulic press hex a flexible water-filled diaphragm 2 disposed between the ram 3 and the saturated textile 4. As demonstrated sequentially in Figures 3, 4 and 5, as the ram 3 engages the saturated textile substrate 4, the flexible diaphragm 2 conforms to the shape-and configuration of the textile substrate bundle inside the press .compartment This equalizes the pressure across the entire textile substrate 4> The result is m even distribution of solution throughout the substrate 4 as it k being squeezed of excess chemical solution. £0001.3] Referring to Figure 3, loading of the press I occurs when the ram 3 Is Initially In the UPPER position, and the mould 5 sits on the bench 6 in the LOWER position. The holt 7 is «witched off. The saturator module partially shown in Figured 3, 4, and 5 of-the apparatus receives the release signal,* the press is ready to be loaded. The mould 5 is loaded with an amount of textile substrate 4 from the saturator module of the apparatus. The photo-electric barrier LSI fer tire slide monitors loading. Alter passage of the textile substrate, once the slide is dear, pressing begins.

[00014] Referring to Figure 4, the hydraulic functions are started by activating the pressure valve Y5. The mm lowers itself using the valve Y4. If the diaphragm is in contact with the to·die substrate, the pressure switch. BS switches to "slowly down'". As a result of the precomprcssiou (ie„ the even application of a small amount of pressure at the beginning) of the 'washing, the operating pressure rises until the admission pressure B7.2 is reached, At the same time, » switchover is made to the ♦‘ptming” function by means of the Yd valve. The pressure increases until the diaphragm pressure preselected is the relevant program is reached. The effect os the textile substrate continues until -the end of the pressing time, wh ich has also been preselected in the program. Pressure switch B5 monitors the diaphragm pressure daring the pressing procedure.

[000151 in addition to the. hydraulic and pressing functions, referred to in the preceding paragraph, three auxiliary functions of the press, namely, hem height, phased pressing, and ventilating can be programmed. $00 ih] Referring to Figure 5, first, there is a reduction in pressure by means of an hydraulic pump (not shown). This Is monitored by pressure switch B7.1. The ram 3 is retracted upwards to an intermediate position above the belt 7 which enables the loosening of the pressed-otit textile substrate 4, (Mote that the slide 10 is shown displaced from its actual position in order to show more clearly the movement of the .ram 8.) If the belt fer holding the textile substrate is ready , the mould travels upwards by means of the valve Y1 The plunger & continues travelling upwards (Y3) until it reaches the position 'Stop at top”. The conveyor belt 7 is activated. Photo-electric barrier LS2 monitors· the passage of the textile substrate 4, After the textile substrate has left the belt sad the latter has come-to a stop, the mould travels downwards by means of the Y2 valve ami returns to its lower position. Pressure switch B7,3 switches the press off in the case of excess pressure in the hydraulic system. (00017] ft is necessary to note that the belt is porous to Skpids, and otherwise allows excess liquid to flow mto the trough 9. In the specific case of the dye site formation, the excess epoxy/alkaiinc solution is captured and reused preferably within a short period. By reintroducing this excess volume, of liquid extracted at the press and returning it by a conduit to the vessel wheat the textile substrate is being loaded and saturated, it is not necessary to discharge this liquid into a sewer system, river, or other discharge receptacle. Effectively, the unahsorbed chemical solution is thus captured and recycled into She saturator unit by this method. It is necessary to add additional chemicals to the saturation unit at a rate sufficient to replace the chemical solution, retained by the previous textile substrate lot and to maintain the concentration at a level that insures proper processing. The chemical liquid feed system is effectively a "closed” system wherein the recycled liquid is stimulated to the vessel repeatedly via the conduit which can be attached, if desired, to an intermediate tank.-for storage of the recycled .chemical solution prior to its reintt'odnetion into She ssiaratorosist, By recapturing add reusing the solution ns shown in Figure 1, over §0% of the cost of the process can be- eliminated In addition to substantially reducing the ecological burden on the environment (00018] Referring again to in Figure 1, after pressing the textile substrate to extract the liquid to be recycled, the substrate is stored, or "batched", for a period of time in the absence of air to allow the pre-treatment chemicals to fully develop the desired dye sites. The treated textile material typically is stored at room temperature lor a period ranging from 8 to 24 hours. Batching must take place in the absence of air because air can uaotraiiae or prevent the reaction from forming the dye sires. A#rstments to the solution formula can extend the time before neutralization occur® bar typically storage under vacuum or is as Inert gas atmosphere is desired. For tbis reason the textiles cm be tightly packed aha bags, drums or containers (taring, the storage and/or heating interval So minim» the destructive exposure to air. The batch time cast be shortened or eiimistated by applying beat tmder strictly controlled casdtfom The "earing* conditions must also be carefully .monitored and adjusted its the absence of air .

[00619} Once the chemical saturation and batching process is complete, the textile substrate can. be· neutralized, washed, and dried as shown is Figure 1 in an economical and highly productive manner by using a. second tunnel washer unit modified to effectively handle the relevant type of textile substrate. Typically,, the process is completed by tumble drying. Suitable dryers, including radio frequency, continuous gas, or mietmv&vedype dryers, can be integrated into the process if desired (00020] The pre-treated textile substrate is new ready for further processing, e,g., spnmmg into yarn, and/or dyeing in an ecologically advantageous and highly efficient manner, IF0021I The method and apparatus for applying predrealments, processing aids, sad finishing agents to fibers, garments and other non-continnous textiles, and a related apparatus to accomplish the method according to the invention have been described with reference to specific embodiments and examples.. Various details of the invention can be changed without departing: from the scope of the invention. Furthermore, the foregoing description ot the preferred embodiments of the invention and 'beet mode lor practicing foe invention are provided for foe purpose of illustration only and not for the purpose of lushing foe scope- of the invention, which is defined by foe following claims.

Claims (5)

1, A method of pre-treating textiles in advance of a dyeing process, comprising. the steps of: fa) loading a textile substrate into a vessel; (b> saturating the textile substrate with pre-treatment chemicals in the vessel; <c) unloading the pre-treated textile substrate from the vessel; (d) loading the textile substrate unloaded in step c into a hydraulic press; (e) exfractittg the pre-treatment chemicals Horn the textile substrate in the press; (i) unloading the textile substrate from the press; and (g) recirculating the extracted pre-treatment chemicals front the press back to the vessel.

2, A method according to claim I wherein; the textile substrate is a non-continuous textile made of celhlosic material; and the textile substrate unloaded In step (f) is stored in the absence of air for a period to allow the pre-treatment chemicals to inly develop the desired dye sites on the ediuiosic molecules of the texti le material.

3, A method according to claim 2 wherein: 'The textile substrate stored lor said period is loaded into a neutral izer/wash -.module .and neutralized, washed, and then dried,

4, .An apparatus for preheating textiles in advance of dying, comprising (k> a vessel for loading a textile substrate and saturating the substrate with pre-tecstmept chemicals; (b) a presain. which the textile substrate in (a) is loaded and squeezed to remove excess pro-treated chemicals; (c) &amp; means for re-cycling non-exhaasted chemicals from the press (b) to the vessel. (a); (iS t a vessel for storing the textile substrate from the press (b) in the absence of air ,'e) a tunnel washing «nit for neutralizing or washing the textile substrate from the storage vessel (d); and ({) a drying machine for drying the textile substrate from the vessel (e).

5, An apparatus according to claim 4 wherein: the vessel (a) is a tunnel washer; the press (b) is a hydraulic press; and the means for recycling nob-exhausted ckemreels from the press (b) to vessel <c) is a conduit» which can fee attached» if desired, to a» intermediate tank- for stomp of the recycled chemical solution prior to its ramirodneiion into tire saturator unit.